Ductless hvac containment system

ABSTRACT

A ductless HVAC containment system is provided, wherein the system is intended to conceal traditional wall hung ductless HVAC components, such as mini split system air handlers. The system may be installed in new construction, retrofits, and during renovations of homes, offices, schools, etc. The system provides an ascetic and functional solution to the growing demand of ductless HVAC units. The system features a cabinet and cover combination engineered to be installed directly into the framing of a wall. The cabinet provides a recess for the air handler and other components that are not in the air handler&#39;s housing. The removable cover conceals the cabinet and provides a means to access the components. Vents and baffles positioned on the removable cover enable control of airflow.

CROSS-REFERENCE TO RELATED APPLICATIONS

N/A

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates generally to heating, ventilation, and air condition (HVAC) systems, but more particularly to a ductless HVAC containment system.

2. Description of Related Art

As the need for high efficiency HVAC increases at home, school, work, and to cool electronic and mechanical spaces, the demand for ductless split systems is increasing every year. However, wall hung ductless split systems are required to use the manufacturer provided air filter which can have limited servicing intervals and can contribute to poor air quality in the temperature controlled space, due to the shelf-like positioning of the return air intake and the associated filter location. Even when all of the associated utilities are installed professionally, the serviceability can be jeopardized and physical components are frequently broken and damaged during the construction process and frequent servicing.

Also, current installations of ductless split systems leave wall mounted equipment fully exposed and require extensive and detailed coordination between the developer, architect, general contractor, and the multiple subcontractors in order to obtain a finished product free from exposed piping, electrical switches and drain components. Concealment of electrical service disconnect switch may require an access panel to hide from the public. The condensate pump and float switch frequently do not fit within the fan control unit housing, which creates condensate drain problems.

Further, ductless split systems protrude into the conditioned space which is unsightly and/or frequently conflicting with electrical code and equipment clearance requirements. This is a problem when fire and electrical inspections are required take place. These are just a few disadvantages of ductless split systems.

BRIEF SUMMARY OF THE INVENTION

The following presents a simplified summary of some embodiments of the invention in order to provide a basic understanding of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some embodiments of the invention in a simplified form as a prelude to the more detailed description that is presented later.

It is an object of the present invention to provide a ductless HVAC containment system having a quality means to tastefully integrate the system into high end living, places of work, education, and utility spaces.

In order to do so, in one aspect of the invention, a ductless HVAC containment system is provided, comprising a cabinet member configured to be positioned within a wall of a home, wherein the cabinet member includes a top portion, a rear portion, a bottom portion, and a pair of side portions, the cabinet member defining a recess to receive a fan coil unit; and, a cover member configured to cover the cabinet member such that the fan coil unit is concealed from view, wherein the cover member includes a plurality of adjustable vent baffles configured enable air flow in and out of the cabinet member.

In one embodiment, a mounting plate is configured to be attached to the rear portion of the cabinet member, wherein the fan coil unit is attached to the mounting plate. In another embodiment, the cabinet member comprises a plurality of openings configured to allow for electrical and conduit connections of the fan coil unit. In yet another embodiment, the plurality of openings are located at least on the pair of side portions. In one embodiment, the cabinet member is constructed from sheet metal. In one embodiment, the cover is removable and configured to retain an air filter. In some embodiments, the fan control unit is a mini-split air handling unit. In some embodiments, a service panel within the cabinet member is provided, wherein the service panel is a removable access panel enabling access to various HVAC components for service and maintenance.

The foregoing has outlined rather broadly the more pertinent and important features of the present disclosure so that the detailed description of the invention that follows may be better understood and so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the disclosed specific methods and structures may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should be realized by those skilled in the art that such equivalent structures do not depart from the spirit and scope of the invention as set forth in the appended claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Other features and advantages of the present invention will become apparent when the following detailed description is read in conjunction with the accompanying drawings, in which:

FIG. 1 is an exploded view of a ductless HVAC containment system according to an embodiment of the present invention;

FIG. 2 shows various views of a cabinet member of the ductless HVAC containment system according to an embodiment of the present invention; and,

FIG. 3 is a transparent section view showing the HVAC containment system installed within a wall according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the general principles of the present invention have been defined herein to specifically provide a ductless HVAC containment system.

Referring to any of the accompanying FIGS. 1-3, the ductless HVAC containment system 100 comprises a cover member 102 and cabinet member 112. In some embodiments, the cover member and the cabinet member are primarily constructed from sheet metal, preferably durable, heavy-gauge sheet metal, however it should be understood that other construction materials may be provided. In one embodiment, the cover member 102 comprises a plurality of adjustable vent baffles 104 configured to enable air flow in and out of the cabinet member 112. Advantageously, the cover member, while routing incoming return air and outgoing supply air, also is configured to conceal all the mechanical, electrical, and HVAC components from view. The removable cover member 102 also provides a means for accessing the FCU (fan coil unit) 300 for service and maintenance. For the purpose of this disclosure, the FCU includes all known fan coil units and air handling units, including ductless mini split systems for heating and cooling. Further, the cover member 102 also provides an insulated barrier between supply and return air to prevent air from bypassing FCU. The FCU will be discussed in greater detail below.

In some embodiments, the cover member 102 allows for the optional installation of a high efficiency air filter (not shown), wherein the air filter improves the air quality and provides longer service intervals of the FCU unit. The air filter may be changed at normal schedules, as well known in the art.

In one embodiment, the cabinet member 112 comprises a rear portion 112A, a top portion 112B, a bottom portion 112C, and a pair of side portions 112D. The cabinet member 122 is a recessed housing configured to house the HVAC components. In some embodiments, the cabinet member 112 includes a mounting plate 106, wherein the mounting plate 106 is configured to be attached to the rear portion 112A of the cabinet member 112. In one embodiment, the FCU unit is configured to be attached to the mounting plate 106 during installation. The details of the installation process will be described below.

During installation, best seen in FIG. 3, the cabinet member 12 is configured to be attached to wall framing 205, wherein the inner wall framing 203 is configured to be cut such that an opening is provided, wherein the opening is a size equal to the outer dimensions of the cabinet member 112. Preferably, when the cabinet member 112 is installed within the wall, a front portion of the cabinet member should be flush with the inner wall framing 203. In one embodiment, the cover member 102 is attached to the inner wall 203 via mounting screws 118. Finishing materials, such as sheet rock 207, may be added, or replaced if removed during the installation process. The mounting locations may vary depending on regulations, restrictions, building codes, etc. For example, in one embodiment, the minimum height below the ceiling 201 is 3 inches and the minimum depth of the cutout opening is 9 inches.

Advantageously, the cabinet's shape ensures proper air flow into and out of the cabinet member 112. Optional dividing members may be installed to separate or contain various components of the HVAC system. For example, in one embodiment, the cabinet contains a means of separation between the low pressure return air and the high pressure supply side of the coil. This ensures high energy efficiency is maintained and air does not bypass the indoor coil. In some embodiments, a service panel 112F provides this function.

In some embodiments, the exterior of the cabinet member 112 is insulated to help prevent heat transfer through the cabinet member portion components to reduce the possibility of condensation on metal surfaces.

In some embodiments, the pair of side portions 112D as well as the top portion 112B includes a plurality of openings 116 configured to allow for electrical and conduit connections as well known in the art, such as refrigerant and drain lines. In some embodiments, a number of mounting brackets 110 are provided to assist in the mounting of the HVAC components. Mounting brackets 114 are configured for mounting the service panel 112F, wherein the service panel is a removable access panel enabling access to various HVAC components for service. In some embodiments, the service panel acts as a baffle member to control the airflow in and out of the cabinet member.

Advantageously, the ductless HVAC containment system of the present invention provides the aesthetics of a traditional central heating and cooling system, i.e. only an air vent is visible to the inhabitants where the system is installed, without any other components of the HVAC system being visible. However, in the present invention, behind the vent (cover member 102) is not ducting like in central heating and cooling systems, but a ductless HVAC air handler (FCU) 300 and other components that do not fit within the FCU housing, including but not limited to, the condensate pump, switches, and valves, as well as other electrical lines and various conduits for operation. Further, these components, like the pump and float switch often create condensate drain problems, so having the cabinet member with optional openings for drain lines as well as insulating material alleviates these concerns.

Although the invention has been described in considerable detail in language specific to structural features, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features described. Rather, the specific features are disclosed as exemplary preferred forms of implementing the claimed invention. Stated otherwise, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. Therefore, while exemplary illustrative embodiments of the invention have been described, numerous variations and alternative embodiments will occur to those skilled in the art. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention.

It should further be noted that throughout the entire disclosure, the labels such as left, right, front, back, top, bottom, forward, reverse, clockwise, counter clockwise, up, down, or other similar terms such as upper, lower, aft, fore, vertical, horizontal, oblique, proximal, distal, parallel, perpendicular, transverse, longitudinal, etc. have been used for convenience purposes only and are not intended to imply any particular fixed direction or orientation. Instead, they are used to reflect relative locations and/or directions/orientations between various portions of an object.

In addition, reference to “first,” “second,” “third,” and etc. members throughout the disclosure (and in particular, claims) are not used to show a serial or numerical limitation but instead are used to distinguish or identify the various members of the group. 

What is claimed is:
 1. A ductless HVAC containment system comprising: a cabinet member configured to be positioned within a wall of a home, wherein the cabinet member includes a top portion, a rear portion, a bottom portion, and a pair of side portions, the cabinet member defining a recess to receive a fan coil unit; and, a cover member configured to cover the cabinet member such that the fan coil unit is concealed from view, wherein the cover member includes a plurality of adjustable vent baffles configured enable air flow in and out of the cabinet member.
 2. The ductless HVAC containment system of claim 1, further comprising a mounting plate configured to be attached to the rear portion of the cabinet member, wherein the fan coil unit is attached to the mounting plate.
 3. The ductless HVAC containment system of claim 1, wherein the cabinet member comprises a plurality of openings configured to allow for electrical and conduit connections of the fan coil unit.
 4. The ductless HVAC containment system of claim 3, wherein the plurality of openings are located at least on the pair of side portions.
 5. The ductless HVAC containment system of claim 1, wherein the cabinet member is constructed from sheet metal.
 6. The ductless HVAC containment system of claim 1, wherein the cover is removable and configured to retain an air filter.
 7. The ductless HVAC containment system of claim 1, wherein the fan control unit is a mini-split air handling unit.
 8. The ductless HVAC containment system of claim 1, further comprising a service panel within the cabinet member, wherein the service panel is a removable access panel enabling access to various HVAC components for service and maintenance. 